Yamaha FZR 400 FAZER Service Repair Manual 1986-1990

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Typ: Motorcycle

Anbieter:

Art.-Nr: 134208

Stichworte: 1986 1987 1988 1989 1990 FAZER FZR 400 Motorcycle Motorcycles Yamaha

Produktvarianten

Beschreibung

Welcome to the comprehensive service manual for the FZR400 Fazer, a celebrated sportbike produced primarily between 1986 and 1990. Known for its lightweight, nimble chassis and responsive inline-four engine, the FZR400 served as an accessible entry into the performance-oriented FZR line. Its design emphasized sporty handling and a dynamic riding experience, making it a popular choice in the entry-level to mid-range sportbike segment of its era. This model, often featuring advanced engineering for its time such as the Deltabox frame, offered a compelling blend of performance and usability, competing effectively with other 400cc sportbikes from major manufacturers. This manual provides in-depth coverage for the FZR400 Fazer (model code 3TJ), encompassing all essential aspects required for maintenance, repair, and troubleshooting. It details procedures for engine mechanicals, fuel and ignition systems, electrical components, suspension, steering, and brakes. Routine maintenance tasks, complex rebuilds, and necessary adjustments are explained with step-by-step instructions and clear diagrams. Technical specifications, fluid recommendations, and insights into common wear items are also included, empowering owners and technicians to keep this iconic sportbike in optimal condition and ensure its longevity.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

FZR400 Fazer

Model Code:

3TJ (typically)

Chassis Type:

Sportbike / Naked Sportbike

Market Segment:

Entry-level to mid-range sportbike

👋 Introduction

Market Position

Positioning In 1980S 1990S:

The FZR400 was positioned as a lightweight, nimble sportbike, often an entry point into Yamaha's FZR line, offering a balance of performance and usability. It competed with other 400cc class bikes like the Honda CBR400 and Kawasaki ZXR400.

Competitive Analysis

Key Competitors:

Honda CBR400 series, Kawasaki ZXR400 series, Suzuki GSX-R400 series, Ducati 750 Sport (in spirit for lighter sportbikes).

Key Features

Defining Characteristics:

Compact size, sporty handling, responsive engine, advanced for its time (e.g., Deltabox frame on some versions), a gateway to higher-performance motorcycles.

Manual Value Proposition

Benefit To Owner:

Empowers owners to perform all necessary maintenance and repairs, saving on dealership costs and fostering a deeper understanding of their motorcycle. Essential for maintaining peak performance and longevity.

📋 Manual Details

Coverage Areas

Countries Of Origin Covered:

Global (primarily Europe, Japan, and North America where sold)

Page Count

Estimated Page Count:

Likely 300-500+ pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Instant Download)

Compatibility

Pc Mac Compatible:

Features

Zoom Functionality:

Delivery

Delivery Method:

Instant Download via Email Link

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full engine disassembly, inspection, repair, and reassembly (cylinder head, valves, pistons, crankshaft, transmission components, clutch, etc.)

Fuel System:

Carburetor adjustment, cleaning, rebuilding, fuel pump, fuel tank, fuel lines

Ignition System:

Ignition timing, coils, spark plugs, CDI unit, wiring

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, switches, wiring diagrams

Suspension And Steering:

Front forks (oil, seals, springs, damping), rear shock absorber, steering head bearings, linkage

Brake System:

Hydraulic front and rear brakes, caliper service, master cylinder overhaul, fluid bleeding, pad replacement

Cooling System:

Radiator, fan, coolant, thermostat, hoses (if liquid-cooled)

Manual Coverage

Chassis And Bodywork:

Frame inspection, fairings, body panels, seat removal, controls

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues

Repair Procedures:

Step-by-step instructions for component removal, repair, and installation

Rebuilds:

Engine rebuilds, carburetor rebuilds, brake system overhauls

Adjustments:

Carburetor synchronization, valve clearances, clutch cable, brake levers

Technical Depth

Depth Of Coverage:

Comprehensive workshop level, covering everything from basic tune-ups to complete engine and transmission rebuilds

📊 Manual Specifications

File Format

File Format:

File Quality

Scanned Quality:

High resolution, clear diagrams and text (as implied by 'easy to follow detailed instructions and step-by-step diagrams')

File Features

Searchable Text:

Likely searchable text within the PDF for quick access to information

Print Quality

Printable:

Yes (allows printing of specific pages or the entire manual)

Binding Type

Binding Type:

N/A (Digital product)

Paper Type

Paper Type:

N/A (Digital product)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, Inline-four cylinder

Displacement:

399 cc (approx. 400 cc)

Bore X Stroke:

56.0 mm x 40.6 mm (typical for 3TJ model)

Compression Ratio:

11.4:1 (typical for 3TJ model)

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 53-55 hp @ 11,000 rpm (depending on market and specific model variant)

Torque:

Approx. 3.7 kg-m (26.8 ft-lbs) @ 9,500 rpm (depending on market and specific model variant)

Fuel System

Fuel Delivery:

Four Mikuni CV carburetors (e.g., Mikuni BDSR32)

Fuel Type:

Unleaded gasoline (Premium recommended)

Lubrication

Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF or SG service classification

Oil Capacity With Filter Change:

Approx. 2.6 liters (2.7 US qt, 2.3 Imp qt)

🔧 Transmission

Standard

Transmission Type:

Constant mesh 6-speed sequential

Features

Clutch Type:

Wet, multiple-disc

Final Drive:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2050 mm (80.7 in)

Overall Width:

Approx. 705 mm (27.8 in)

Overall Height:

Approx. 1135 mm (44.7 in)

Wheelbase:

Approx. 1375 mm (54.1 in)

Weights

Dry Weight:

Approx. 158 kg (348 lbs)

Wet Weight:

Approx. 175 kg (386 lbs) (with all fluids)

Fuel Tank Capacity:

15 liters (3.96 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings are not standardized like automotive crash tests)

Active Features

Braking System:

Dual front disc brakes, single rear disc brake, hydraulic actuation

Suspension Features:

Upside-down front forks (on some models), adjustable rear monoshock

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a 1980s/1990s motorcycle; no integrated infotainment)

Driver Assistance

Electronic Aids:

Limited; basic electronic ignition (CDI). No ABS or traction control.

Instrumentation

Dashboard Features:

Analog speedometer, tachometer, fuel gauge, odometer, trip meter, warning lights (oil pressure, neutral, turn signals, high beam).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first

Chain Cleaning Lubrication:

Every 500-1,000 km (300-600 miles) and after riding in wet conditions

Air Filter Inspection:

Every 3,000-5,000 km (1,800-3,000 miles), clean or replace as needed

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles)

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation)

Coolant Type:

Ethylene glycol-based antifreeze coolant (50% mixture with distilled water)

Known Issues

Common Wear Items:

Carburetor synchronization drift, fork seal leaks, aging electrical connectors, cam chain tensioner wear.

Performance Issues:

Hesitation or flat spots due to carburetors needing cleaning/synchronization, potential stator failure affecting charging.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha has a long and successful history in motorcycle racing and production, known for innovation and performance across various categories, including sportbikes.

Model Evolution

Fzr Lineage:

The FZR400 was part of Yamaha's advanced FZR sportbike family, which included larger displacement models like the FZR600, FZR750R, and the legendary FZR1000. It shared technology and design philosophies.

Production

Production Years:

1986-1990 (for the specific generation covered by this manual)

Manufacturing Locations:

Primarily Japan

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

Specific awards for the FZR400 are not widely documented in the same way as modern vehicles, but it was generally well-received as a competent and engaging sportbike in its class.